2009 Kenworth C500 problems, complaints & recalls
Safety recalls (4)
Service Brakes, Air:supply:reservoir/Tank 2024-02-23 ยท campaign 24V145000 ยท 936 vehicles
Defect: PACCAR Incorporated (PACCAR) is recalling certain 2009-2021 Kenworth C500, 2012-2021 Kenworth T440, 2009-2015 Kenworth T660, 2015-2024 Kenworth T680, 2009-2024 Kenworth T800, 2009-2020 Kenworth T370, 2014-2023 Kenworth T880, 2011-2016 Kenworth T470, 2023 Kenworth T480, and 2009-2019 Kenworth W900 vehicles. The air tanks have an insufficient volume of air for the brake system. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 121, "Air
Risk: Insufficient air volume can reduce braking performance and increase the risk of a crash.
Fix: Dealers will install the correct volume air tanks, free of charge. Owner notification letters were mailed August 12, 2024. Additional owner notification letters were mailed October 27, 2025. Owners may contact PACCAR customer service at 1-425-828-5888. PACCAR's number for this recall is 24KWD.
Engine And Engine Cooling 2011-03-24 ยท campaign 11V203000 ยท 5,831 vehicles
Defect: PACCAR IS RECALLING CERTAIN MODEL YEAR 2007-2011 KENWORTH C500, T2000, T600, AND T660, AS WELL AS MODEL YEAR 2009-2011 PETERBILT 387 AND 388 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINE AND MANUFACTURED FROM MAY 11, 2006, THROUGH SEPTEMBER 17, 2010. DEGRADATION OF A COMBUSTION TUBE WELD CAN CAUSE RADIAL HEAT IMPINGEMENT ON THE BODY WHICH MAY BURN THROUGH CERTAIN BODIES USED ON C15 ENGINES.
Risk: THIS COULD RESULT IN A FIRE.
Fix: CATERPILLAR IS HANDLING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. PLEASE SEE CATERPILLAR'S DEFECT REPORT 11E-006. CATERPILLAR WILL REPLACE THE SINGLE PIECE COMBUSTION TUBE WITH A THICK WALL COMBUSTION TUBE WHICH WILL NOT ALLOW THE HEAT TO BREAK THROUGH. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. DUE TO A PARTS SUPPLY ISSUE, OWNERS WILL BE NOTIFIED BY THE END OF APRIL 2011 ABOUT THE SAFETY DEFECT, AND WILL THEN BE NOTIFIED AGAIN ONCE THE FREE REMEDY IS AVAILABLE, CURRENTLY ESTIMA
Steering:column 2010-07-02 ยท campaign 10V308000 ยท 9,697 vehicles
Defect: PACCAR IS RECALLING CERTAIN MODEL YEAR 2008-2010 TRUCKS EQUIPPED WITH TRW STEERING SHAFTS. THE CIRCUMFERENTIAL WELD AROUND THE STEERING SHAFT TUBE THAT WELDS THE SPLINED TUBE TO THE NON-SPLINED TUBE MAY BE MISLOCATED. MISLOCATION OF THE CIRCUMFERENTIAL WELD MAY ALLOW THE SPLINED TUBE AND NON-SPLINED TUBE TO ROTATE RELATIVE TO ONE ANOTHER DURING A LOW SPEED, HIGH TORQUE TURN, POSSIBLY RESULTING IN A SEPARATION OF THE TWO TUBES.
Risk: A SEPARATION OF THE SPLINED AND NON-SPLINED TUBES WOULD CAUSE A LOSS OF STEERING CONTROL AND INCREASE THE RISK OF A VEHICLE CRASH.
Fix: DEALERS WILL INSPECT THE STEERING SHAFT USING A WELD PLACEMENT GAUGE PROVIDED BY TRW. ANY STEERING SHAFT FOUND TO HAVE BEEN WELDED IMPROPERLY WILL BE REPLACED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 30, 2010. OWNERS MAY CONTACT KENWORTH AT 425-828-5440 AND PETERBILT AT 940-591-4196.
Structure:body:hood 2010-05-18 ยท campaign 10V212000 ยท 10 vehicles
Defect: KENWORTH IS RECALLING CERTAIN MODEL YEAR 2009 THROUGH 2011 C500 TRUCKS MANUFACTURED FROM OCTOBER 24, 2008 THROUGH JANUARY 13, 2010. DURING MANEUVERS WITH CERTAIN COMBINATIONS OF WHEEL TURN, ARTICULATION, AND BUMP, THE BRAKE CHAMBER CAN CONTACT THE REAR HOOD SUPPORT.
Risk: THE CONTACT CAN DAMAGE THE BRAKE CHAMBER LEADING TO A LOSS OF BRAKING FUNCTION AT THE AFFECTED WHEEL END, INCREASING THE RISK OF A CRASH.
Fix: KENWORTH WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 8, 2010. OWNERS MAY CONTACT KENWORTH AT 1-425-828-5440.
Service bulletins (12)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free โ but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Unknown Or Other 2026-10-13 ยท 42-070 ยท Service Bulletin/Repair Instructions
due to supplier constraints, an authorized aftermarket surge tank has been made available.
Engine 2026-09-11 ยท P001 ยท Service Bulletin/Repair Instructions
"kenworth: dealers should check the chassis list and sir weekly for vin changes. 2 chassis added to the chassis list. peterbilt: dealers should check the chassis list and sir weekly for vin changes. 10 chassis added to the chassis list."
Service Brakes, Air 2024-04-09 ยท 24KWD ยท Service Bulletin/Repair Instructions
certain c500/t440/t470/t660/t680/t800/t880/w900 chassis may have air tank reservoirs that do not meet air volume requirements per fmvss/cmvss 121 รฃยขรขยรขยair brake systemsรฃยขรขยรขย. this bulletin will be updated when repair parts and procedures are available.
Visibility:windshield Wiper/Washer 2021-02-10 ยท 02-160 ยท Service Bulletin/Repair Instructions
information only รขยย windshield washer pumps have a high no trouble found rate. washer pumps may fail to spray due to a clogged filter.
Electrical System 2020-06-08 ยท 32-015 ยท Service Bulletin/Repair Instructions
information only: this bulletin provides dealers with a battery warranty quick reference guide to ensure the appropriate tests for battery warranty are performed in order to prevent battery warranty claims filed with incorrect or incomplete information.
Equipment 2020-03-17 ยท 32-016 ยท Service Bulletin/Repair Instructions
information only: proper jump-starting voltage will eliminate high voltage related issues and equipment damage.
Showing the 6 most recent of 12 bulletins. Search all of them free at nhtsa.gov.
What owners report
No detailed complaint narratives on file.
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.